CN101070595A - Method and apparatus for preparing material coating by laser inductive composite melt-coating - Google Patents
Method and apparatus for preparing material coating by laser inductive composite melt-coatingDownload PDFInfo
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Abstract
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Description
Translated fromChinese技术领域technical field
本发明属于激光加工技术领域，具体涉及一种激光感应复合熔覆制备材料涂层的方法及装置。The invention belongs to the technical field of laser processing, and in particular relates to a method and a device for preparing a material coating by laser induction composite cladding.
背景技术Background technique
激光熔覆技术是采用高能量密度的激光束在工件表面熔覆一层特殊性能的材料，以改善其表面性能的工艺。与传统的堆焊与热喷涂工艺相比，激光熔覆技术具有如下优点：(1)激光束光斑小且能量密度高，在熔覆过程中可以将工件的热影响区与热变形降低到最小程度；(2)通过调节工艺参数，可以获得稀释率小于10％的熔覆层；(3)熔覆层与基材为冶金结合，结合强度高，不易剥落；(4)通过专门设计的激光导光装置，可以对深孔、内孔和凹槽等部位进行激光熔覆处理，结合多道多层技术可以获得满足不同尺寸要求的熔覆涂层；(5)激光熔覆技术对环境无污染，自动化程度高。因此，在汽车、冶金、航空航天、船舶、轨道运输等领域具有十分广阔的应用前景。Laser cladding technology is a process of cladding a layer of material with special properties on the surface of a workpiece by using a high-energy-density laser beam to improve its surface properties. Compared with traditional surfacing and thermal spraying processes, laser cladding technology has the following advantages: (1) The laser beam spot is small and the energy density is high, which can minimize the heat-affected zone and thermal deformation of the workpiece during the cladding process (2) By adjusting the process parameters, the cladding layer with a dilution rate of less than 10% can be obtained; (3) The cladding layer and the substrate are metallurgically bonded, with high bonding strength and not easy to peel off; (4) Through a specially designed laser The light guide device can carry out laser cladding treatment on deep holes, inner holes and grooves, etc., combined with multi-layer multi-layer technology, cladding coatings that meet different size requirements can be obtained; (5) laser cladding technology is environmentally friendly Pollution, high degree of automation. Therefore, it has very broad application prospects in the fields of automobile, metallurgy, aerospace, shipbuilding, rail transportation and so on.
然而，到目前为止，激光熔覆技术在工业中的应用程度并未达到早期预想的目标，主要原因包括：(1)高功率激光加工设备的一次性投资较大，且维护费用昂贵；(2)激光熔覆效率远低于传统工艺，如堆焊与热喷涂，因此单位面积涂层的制造成本偏高；(3)虽然可以将激光与热喷涂结合起来实现激光热喷涂复合熔覆技术(J.Suutala，J.Tuominen，P.Vuoristo.Laser-assisted spraying and laser treatment of thermally sprayedcoatings，Surface & coatings Technology，201(2006)：1981-1987)，使激光熔覆效率提高，但由于激光熔覆过程的快速加热与快速冷却凝固、热应力大的特点，在大块材料表面进行激光熔覆时，熔覆层极易产生裂纹。特别是在可焊性差的基材表面，裂纹问题一直是激光熔覆层难以逾越的障碍之一，制约了该技术的工业化应用。However, so far, the application of laser cladding technology in industry has not reached the early expected goal. The main reasons include: (1) the one-time investment of high-power laser processing equipment is relatively large, and the maintenance cost is expensive; (2) ) The efficiency of laser cladding is much lower than that of traditional processes, such as surfacing and thermal spraying, so the manufacturing cost per unit area of the coating is relatively high; (3) although laser and thermal spraying can be combined to achieve laser thermal spraying composite cladding technology ( J.Suutala, J.Tuominen, P.Vuoristo.Laser-assisted spraying and laser treatment of thermally sprayed coatings, Surface & coatings Technology, 201(2006): 1981-1987), which improved the efficiency of laser cladding, but due to laser cladding Due to the characteristics of rapid heating, rapid cooling and solidification, and large thermal stress in the process, when laser cladding is performed on the surface of bulk materials, cracks are easily generated in the cladding layer. Especially on the surface of substrates with poor weldability, the problem of cracks has always been one of the insurmountable obstacles of laser cladding, which restricts the industrial application of this technology.
对基材进行预热处理，降低熔覆层的冷却速度及与基材间的温度梯度，被认为是消除裂纹的最有利方法。Yoshiwara与Kawaname(Method forsurface alloying metal with a high density energy beam and an alloysteel，United States，United States Patent，4750947，1988)采用加热炉或氧乙炔火焰将工件预热到600-800℃，在激光熔覆速度达5.4米/分钟的条件下，获得了无裂纹的熔覆层。这种采用预热的激光熔覆技术与单纯的激光熔覆技术相比较，在相同工艺参数条件下熔覆效率提高了225％。但是，对于形状复杂与尺寸大的工件，预热时需要复杂的加热炉，而且长时间的保温在工件表面会产生氧化皮，严重影响激光熔覆层的质量。此外，经过预热之后在高温的环境中装卸与夹持工件也很不方便，不但工作效率低，还容易灼伤操作人员。而采用氧乙炔火焰进行预热，工件的受热过程慢，热影响区较大，导致基材组织粗大，机械性能恶化。此外，采用上述两种方法只能够对外观简单的零部件进行激光熔覆加工，无法对复杂零部件或者空心部件的内壁进行激光熔覆处理。而且在激光熔覆处理的同时无法对难焊接或大型工件进行后热缓冷处理，因此，其装置的通用性不强。Preheating the substrate to reduce the cooling rate of the cladding layer and the temperature gradient between the substrate and the substrate is considered to be the most favorable method to eliminate cracks. Yoshiwara and Kawaname (Method for surface alloying metal with a high density energy beam and an alloysteel, United States, United States Patent, 4750947, 1988) used a heating furnace or an oxyacetylene flame to preheat the workpiece to 600-800°C, and then laser cladding Under the condition of speed up to 5.4 m/min, a crack-free cladding layer was obtained. Compared with the pure laser cladding technology, this preheating laser cladding technology has a 225% increase in cladding efficiency under the same process parameters. However, for workpieces with complex shapes and large sizes, complex heating furnaces are required for preheating, and long-term heat preservation will produce scale on the surface of the workpiece, which seriously affects the quality of the laser cladding layer. In addition, it is inconvenient to load, unload and clamp workpieces in a high-temperature environment after preheating. Not only is the work efficiency low, but it is also easy to burn the operator. However, the oxyacetylene flame is used for preheating, the heating process of the workpiece is slow, and the heat-affected zone is large, resulting in a coarse structure of the substrate and deterioration of mechanical properties. In addition, the above two methods can only be used for laser cladding processing of parts with simple appearance, and cannot be used for laser cladding processing of complex parts or the inner wall of hollow parts. Moreover, it is impossible to perform post-heating and slow-cooling treatment on difficult-to-weld or large-scale workpieces during laser cladding treatment, so the versatility of the device is not strong.
近年来，操作方便的感应加热熔覆技术，引起了人们的广泛兴趣。感应熔覆加工技术可以获得大面积的熔覆层，生产成本低，效率高。该技术的不足之处在于：(1)待熔覆材料需要预涂于基材表面，熔覆准备工作量较大；(2)熔化必须控制在液一固两相之间，易出现熔覆层流失，因而熔覆层的致密性稍差；(3)感应熔覆过程中，所能够达到的最高温度有限，因此对于一些高熔点的合金层难以实现熔覆加工；(4)单纯感应熔覆所需要消耗的能量大，易产生基体过热，产品质量不易控制。In recent years, the easy-to-operate induction heating cladding technology has aroused widespread interest. Induction cladding processing technology can obtain a large area of cladding layer, with low production cost and high efficiency. The disadvantages of this technology are: (1) The material to be clad needs to be pre-coated on the surface of the substrate, and the cladding preparation workload is relatively large; (2) The melting must be controlled between the liquid and solid phases, which is prone to cladding (3) In the process of induction cladding, the maximum temperature that can be reached is limited, so it is difficult to achieve cladding processing for some alloy layers with high melting point; (4) Pure induction cladding Covering consumes a lot of energy, it is easy to cause overheating of the substrate, and the product quality is not easy to control.
发明内容Contents of the invention
本发明的目的在于提供激光感应复合熔覆制备材料涂层的方法，该方法的熔覆效率高，熔覆层产生气孔与裂纹的几率大幅度下降，整体质量全面提高；本发明还提供了实现该方法的装置，该装置通用性较强，可以对实心部件的表面及空心部件的内外表面进行激光熔覆处理。The object of the present invention is to provide a method for preparing a material coating by laser induction composite cladding. The cladding efficiency of the method is high, the probability of pores and cracks in the cladding layer is greatly reduced, and the overall quality is comprehensively improved; the present invention also provides a method for realizing The device of the method has strong versatility, and can perform laser cladding treatment on the surface of the solid component and the inner and outer surfaces of the hollow component.
本发明提供的激光感应复合熔覆制备材料涂层的方法，其步骤包括：The method for preparing a material coating by laser induction composite cladding provided by the present invention, the steps include:
①在已进行过喷砂处理的待加工工件表面喷涂一层厚度为0.1-3.0毫米的涂层，涂层材料为合金粉末，或者合金粉末与陶瓷相颗粒形成的金属陶瓷复合粉末，其中陶瓷相颗粒的质量百分含量小于等于70％；① Spray a layer of coating with a thickness of 0.1-3.0 mm on the surface of the workpiece to be processed that has been sandblasted. The coating material is alloy powder, or a metal-ceramic composite powder formed by alloy powder and ceramic phase particles. The mass percentage of particles is less than or equal to 70%;
②将待加工工件表面的涂层与感应加热线圈之间的距离控制在1-10毫米范围内，利用高频感应加热器往感应加热线圈内通入电流，使工件表面的温度为500-1200℃，并通入保护气体；② Control the distance between the coating on the surface of the workpiece to be processed and the induction heating coil in the range of 1-10 mm, and use a high-frequency induction heater to pass current into the induction heating coil to make the surface temperature of the workpiece 500-1200 ℃, and pass through the protective gas;
③将激光束聚焦之后辐照在感应加热区内，对涂层进行激光熔覆处理，激光功率为1-10KW，激光束的光斑直径为2-30毫米，激光熔覆线速度为0.5-10米/分钟，感应加热功率为10-300KW；③ Focus the laser beam and irradiate it in the induction heating zone, and then carry out laser cladding treatment on the coating. m/min, induction heating power is 10-300KW;
④在熔覆完一层合金涂层之后，检测熔覆层的厚度是否达到设定的厚度要求，如果没有，重复步骤①-③，直到熔覆层达到所需要的厚度，否则，工作结束。④After cladding a layer of alloy coating, check whether the thickness of the cladding layer reaches the set thickness requirement, if not, repeat steps ①-③ until the cladding layer reaches the required thickness, otherwise, the work ends.
实现上述方法的装置包括激光器、激光导光装置、激光聚焦装置、数控机床与工件夹持装置，激光器、激光导光装置和激光聚焦装置位于同一光路上，激光器发射出来的激光束经激光导光装置传输到激光聚焦装置，经聚焦后照射至工件表面的预置涂层，导气管的出气口位于激光聚焦装置的出光口处，工件夹持装置安装在数控机床上；其特征在于：该装置还包括高频感应加热器，感应加热线圈与高频感应加热器相连，工作时，感应加热线圈与待加工工件涂层之间的距离为1-10毫米。The device for realizing the above method includes a laser, a laser light guiding device, a laser focusing device, a numerical control machine tool and a workpiece clamping device. The laser, the laser light guiding device and the laser focusing device are located on the same optical path, and the laser beam emitted by the laser is guided through the laser light The device is transmitted to the laser focusing device, and after focusing, it irradiates to the preset coating on the surface of the workpiece. The air outlet of the air duct is located at the light outlet of the laser focusing device, and the workpiece clamping device is installed on the CNC machine tool; it is characterized in that: the device It also includes a high-frequency induction heater. The induction heating coil is connected with the high-frequency induction heater. When working, the distance between the induction heating coil and the coating of the workpiece to be processed is 1-10 mm.
本发明避免了常规加热方法(如加热炉或气体火焰等)预热实现激光熔覆时存在的效率低、易造成重要部件损坏等问题，利用热喷涂、冷喷涂以及超音速火焰喷涂技术效率高的优点，将高能激光束与高频电磁感应加热器结合起来，实现激光与感应加热复合熔覆的过程。与单纯的激光熔覆技术或感应熔覆技术等工艺方法相比，本发明具有以下技术效果：The present invention avoids the problems of low efficiency and easy damage to important components when preheating by conventional heating methods (such as heating furnace or gas flame, etc.) to realize laser cladding, and utilizes thermal spraying, cold spraying and supersonic flame spraying technology to have high efficiency The advantages of combining high-energy laser beams with high-frequency electromagnetic induction heaters realize the process of composite cladding of laser and induction heating. Compared with pure laser cladding technology or induction cladding technology and other processes, the present invention has the following technical effects:
(1)本发明的感应加热装置结构简单，使用方便，开启迅速，可以避免常规加热方法如加热炉或气体火焰等易造成重要部件损坏以及熔覆效率低的问题；(1) The induction heating device of the present invention is simple in structure, easy to use, and can be opened quickly, which can avoid the problems of damage to important parts and low cladding efficiency caused by conventional heating methods such as heating furnaces or gas flames;
(2)本发明中的感应加热器由单匝或多匝感应加热线圈组成，感应加热线圈的形状为圆环或一段圆弧，安装定位方便；感应加热器可以对工件完成预热、后热或预热与后热同时进行的加热处理；被加热的工件不需要与感应加热线圈接触，加热时间短，装卸方便。具体而言，感应加热源的引入实际上有两个优点：一是对工件实现预热，使工件的温度提高之后，激光的能量主要消耗在熔化合金粉末上，因此激光能量利用率大大提高，熔覆速度也可以得到大幅度提升，达到0.5-10米/分钟甚至更高，比现有的激光熔覆的速度提高了1-10倍。粉末沉积率为1-15千克/小时，比现有的激光熔覆的沉积率提高了1-15倍；二是感应加热线圈可以对激光熔覆之后的工件表面实现后热缓冷，降低其冷却速度，因此可以减少熔覆层的开裂敏感性，提高熔覆层的质量和性能。(2) The induction heater among the present invention is made up of single-turn or multi-turn induction heating coil, and the shape of induction heating coil is a ring or a section of circular arc, and installation and positioning are convenient; Induction heater can finish preheating, postheating to workpiece Or preheating and postheating heat treatment at the same time; the workpiece to be heated does not need to be in contact with the induction heating coil, the heating time is short, and the loading and unloading is convenient. Specifically, the introduction of the induction heating source actually has two advantages: one is to preheat the workpiece, and after the temperature of the workpiece is increased, the energy of the laser is mainly consumed on the melting alloy powder, so the utilization rate of laser energy is greatly improved. The cladding speed can also be greatly improved, reaching 0.5-10 m/min or even higher, which is 1-10 times faster than the existing laser cladding speed. The powder deposition rate is 1-15 kg/hour, which is 1-15 times higher than that of the existing laser cladding; secondly, the induction heating coil can realize post-heat and slow cooling on the surface of the workpiece after laser cladding, reducing its The cooling rate, thus reducing the cracking susceptibility of the cladding and improving the quality and performance of the cladding.
(3)采用本发明装置易于将需要加热的区域限定在工件的局部区域，而不必对工件进行整体加热，因此对工件的尺寸、形状、需要处理的部位无限制。(3) Adopting the device of the present invention can easily limit the area to be heated to a local area of the workpiece without heating the workpiece as a whole, so there is no limit to the size, shape, and parts of the workpiece to be treated.
(4)可以制备各种高性能涂层，例如高温合金涂层、耐磨合金涂层或者金属陶瓷复合涂层等。其中陶瓷相的质量百分含量高达70％，而且整个金属陶瓷复合涂层与基材呈冶金结合，且几乎不产生气孔与裂纹。(4) Various high-performance coatings can be prepared, such as superalloy coatings, wear-resistant alloy coatings or metal-ceramic composite coatings. The mass percentage of the ceramic phase is as high as 70%, and the entire metal-ceramic composite coating is metallurgically combined with the base material, and almost no pores and cracks are generated.
(5)对于可焊性差的材质如高铬铸铁、锻钢与高碳高合金钢等，利用本发明方法可以获得无气孔、无裂纹、高性能的材料涂层。因此，对于加工大尺寸工件如大型轧辊、曲轴与管状零件等优势十分明显，应用前景十分广阔。(5) For materials with poor weldability, such as high-chromium cast iron, forged steel and high-carbon high-alloy steel, etc., the method of the present invention can obtain a high-performance material coating without pores and cracks. Therefore, it has obvious advantages in processing large-sized workpieces such as large rolls, crankshafts and tubular parts, and its application prospects are very broad.
本发明可用于各种实心部件的表面与空心部件内外壁的表面处理。The invention can be used for surface treatment of various solid parts and inner and outer walls of hollow parts.
附图说明Description of drawings
图1a为激光束定位到感应加热线圈之间时对空心部件的外表面进行激光感应复合熔覆高性能材料涂层的装置示意图；Figure 1a is a schematic diagram of a device for performing laser induction composite cladding of a high-performance material coating on the outer surface of a hollow part when the laser beam is positioned between the induction heating coils;
图1b为激光束定位到感应加热线圈之后时对空心部件的外表面进行激光感应复合熔覆高性能材料涂层的装置示意图；Figure 1b is a schematic diagram of a device for performing laser induction composite cladding high-performance material coating on the outer surface of a hollow part when the laser beam is positioned behind the induction heating coil;
图2为专用于空心部件外表面激光感应复合熔覆装置各个主要部件的布置示意图；Figure 2 is a schematic diagram of the layout of the main components of the laser induction composite cladding device dedicated to the outer surface of hollow parts;
图3为专用于实心部件表面激光感应复合熔覆的半圆形感应加热线圈与工件的布置示意图；Figure 3 is a schematic diagram of the layout of the semicircular induction heating coil and the workpiece dedicated to laser induction composite cladding on the surface of solid components;
图4为对实心部件表面进行激光感应复合熔覆高性能材料涂层的装置示意图；Fig. 4 is a schematic diagram of a device for laser induction composite cladding high-performance material coating on the surface of a solid component;
图5为对空心部件内表面进行激光感应复合熔覆高性能材料涂层的装置示意图；Fig. 5 is a schematic diagram of a device for performing laser induction composite cladding high-performance material coating on the inner surface of a hollow part;
图6为专用于空心部件内表面激光感应复合熔覆高性能材料涂层的激光导光装置示意图；Figure 6 is a schematic diagram of a laser light guide device dedicated to laser induction composite cladding of high-performance material coatings on the inner surface of hollow parts;
图7为专用于空心部件内表面激光感应复合熔覆装置各个主要部件的布置示意图；Figure 7 is a schematic diagram of the layout of the main components of the laser induction composite cladding device dedicated to the inner surface of hollow parts;
具体实施方式Detailed ways
本发明方法利用激光感应复合熔覆技术，通过多道多层搭接熔覆方式，可在工件内外表面快速获得满足工件尺寸规格要求、无气孔与无裂纹、与基材呈冶金结合的高性能材料涂层。下面结合附图和实例对本发明作进一步说明。The method of the present invention utilizes the laser induction composite cladding technology, and through the multi-layer overlapping cladding method, the inner and outer surfaces of the workpiece can quickly obtain high performance that meets the size specification requirements of the workpiece, has no pores and cracks, and is metallurgically combined with the base material. material coating. The present invention will be further described below in conjunction with accompanying drawing and example.
本发明提出的激光感应复合熔覆高性能材料涂层的方法，其实施步骤包括：The method for laser induction composite cladding high-performance material coating proposed by the present invention, its implementation steps include:
(1)先将待加工工件的表面进行喷砂处理，为热喷涂、冷喷涂或超音速火焰喷涂预置合金涂层奠定基础；(1) Sandblasting the surface of the workpiece to be processed first, laying the foundation for thermal spraying, cold spraying or supersonic flame spraying preset alloy coating;
(2)在待加工工件表面喷涂一层厚度为0.1-3.0毫米的涂层，待加工工件为已进行过喷砂处理的实心部件或空心管件，涂层材料为合金粉末(包括自熔合金粉末或其它非自熔合金粉末)、或者在上述合金粉末中掺入最大质量百分含量可达70％的陶瓷相颗粒(如碳化钨、碳化钛、碳化硅等高硬度陶瓷材料)而形成的金属陶瓷复合粉末。喷涂预置层可以采用冷喷涂、热喷涂或者超音速火焰喷涂等；(2) Spray a layer of coating with a thickness of 0.1-3.0 mm on the surface of the workpiece to be processed. The workpiece to be processed is a solid part or hollow pipe that has been sandblasted. The coating material is alloy powder (including self-fluxing alloy powder or other non-self-fluxing alloy powders), or a metal formed by mixing ceramic phase particles (such as tungsten carbide, titanium carbide, silicon carbide and other high-hardness ceramic materials) with a maximum mass percentage of up to 70% in the above alloy powder Ceramic composite powder. Spraying the preset layer can be done by cold spraying, thermal spraying or supersonic flame spraying, etc.;
(3)将待加工工件表面的涂层与感应加热线圈之间的距离控制在1-10毫米范围内，利用高频感应加热器往感应加热线圈内通入电流，使待加工工件表面的温度为500-1200℃。(3) Control the distance between the coating on the surface of the workpiece to be processed and the induction heating coil within the range of 1-10 mm, and use a high-frequency induction heater to pass current into the induction heating coil to make the surface temperature of the workpiece to be processed 500-1200°C.
对待加工工件的外壁进行处理时，在待加工工件的处理区域通入保护气体，可防止工件氧化。也可以先对已进行过喷砂处理的待加工工件表面进行感应加热，然后在感应加热区利用热喷涂、冷喷涂或超音速火焰喷涂技术在待加工工件表面喷涂0.1-3毫米的涂层，最后进行激光熔覆处理。在进行激光熔覆处理的过程中，调节感应加热功率，使待处理的区域温度在500-1200℃范围内。When the outer wall of the workpiece to be processed is processed, a protective gas is introduced into the processing area of the workpiece to prevent oxidation of the workpiece. It is also possible to inductively heat the surface of the workpiece that has been sandblasted, and then use thermal spraying, cold spraying or supersonic flame spraying technology in the induction heating area to spray a coating of 0.1-3 mm on the surface of the workpiece to be processed. Finally, laser cladding is performed. During the laser cladding process, the induction heating power is adjusted so that the temperature of the area to be treated is within the range of 500-1200°C.
(4)将激光束聚焦之后辐照在感应加热区内，对涂层进行激光熔覆处理，激光功率为1-10KW，激光束的光斑直径为2-30毫米，激光熔覆线速度为0.5-10米/分钟，感应加热功率为10-300KW。(4) After the laser beam is focused, it is irradiated in the induction heating zone, and the coating is subjected to laser cladding treatment. The laser power is 1-10KW, the spot diameter of the laser beam is 2-30 mm, and the laser cladding line speed is 0.5 -10m/min, induction heating power is 10-300KW.
对于难焊接材料或大型工件，聚焦后的激光束定位到感应加热线圈之间，实现工件激光熔覆处理后的后热缓冷，降低熔覆层的冷却速度，因此可以减少熔覆层的开裂敏感性，提高熔覆层的质量和性能。对于小型工件，可以将激光束定位到感应加热线圈之后(相对于工件的轴向运动方向)一定距离的感应加热区内。当激光束定位到感应加热线圈之间时，具体感应加热线圈的匝数及用于预热与后热的线圈匝数根据工况要求选择。For difficult-to-weld materials or large workpieces, the focused laser beam is positioned between the induction heating coils to realize post-heat slow cooling of the workpiece after laser cladding treatment and reduce the cooling rate of the cladding layer, thus reducing the cracking of the cladding layer Sensitivity, improving cladding quality and performance. For small workpieces, the laser beam can be positioned within the induction heating zone at a distance behind the induction heating coil (relative to the direction of axial motion of the workpiece). When the laser beam is positioned between the induction heating coils, the specific number of turns of the induction heating coil and the number of coil turns for preheating and postheating are selected according to the requirements of the working conditions.
对于轴类零件，当工件旋转的同时，沿工件的轴向移动数控机床，使激光束在工件的表面呈螺旋线方式扫描。通过调节数控机床移动的距离，从而控制熔覆层的搭接率，工件每旋转一周，则数控机床沿工件的轴向移动的距离一般为激光光斑直径的30％-70％。对于平板类零部件，当熔覆完一道之后，沿垂直于激光扫描方向移动数控机床，使相邻激光熔覆道次的搭接率控制在激光束光斑直径的30％-70％。具体值取决于对激光加工工艺的要求。For shaft parts, when the workpiece is rotating, the CNC machine tool is moved along the axial direction of the workpiece, so that the laser beam scans the surface of the workpiece in a helical manner. By adjusting the moving distance of the CNC machine tool, the overlapping rate of the cladding layer is controlled. The distance that the CNC machine tool moves along the axis of the workpiece is generally 30%-70% of the diameter of the laser spot for each rotation of the workpiece. For flat parts, after one pass of cladding, move the CNC machine tool perpendicular to the laser scanning direction, so that the overlapping rate of adjacent laser cladding passes is controlled at 30%-70% of the diameter of the laser beam spot. The specific value depends on the requirements of the laser processing technology.
(5)在熔覆完一层合金涂层之后，检测熔覆层的厚度是否达到设定的厚度要求。如果没有，在原有第一层熔覆层的基础上，重复步骤(2)-(4)，直到熔覆层达到所需要的厚度。在重复上述步骤时，所要注意的是调整激光聚焦装置与工件表面涂层之间的距离，并注意感应加热线圈与工件表面涂层之间间隙大小的调节，以便确保激光熔覆时光斑大小和感应加热线圈加热时的热效应不变。如果熔覆层已经达到所需要的厚度，则工作结束。(5) After cladding a layer of alloy coating, check whether the thickness of the cladding layer meets the set thickness requirement. If not, repeat steps (2)-(4) on the basis of the original first cladding layer until the cladding layer reaches the required thickness. When repeating the above steps, what should be paid attention to is to adjust the distance between the laser focusing device and the surface coating of the workpiece, and pay attention to the adjustment of the gap between the induction heating coil and the surface coating of the workpiece, so as to ensure the spot size and The thermal effect does not change when the induction heating coil is heated. If the cladding layer has reached the required thickness, the job is over.
在激光感应复合熔覆过程中，由于感应加热可以在工件表面一定厚度区域内产生一定的温度场，大大地降低了熔覆层在凝固过程中与基材之间的温度梯度，不但有利于熔覆层中气泡的溢出，而且可以将熔覆层中的残余应力降低到最小值，有利于抑制熔覆层中裂纹的产生。In the process of laser induction composite cladding, because induction heating can generate a certain temperature field in a certain thickness area on the surface of the workpiece, it greatly reduces the temperature gradient between the cladding layer and the substrate during the solidification process, which is not only beneficial to the melting The overflow of bubbles in the cladding layer can reduce the residual stress in the cladding layer to a minimum, which is beneficial to suppress the generation of cracks in the cladding layer.
如图1a与1b所示的装置，本发明装置包括激光器1、激光导光装置4、激光聚焦装置3、高频感应加热器2、数控机床6与工件夹持装置。As shown in Figures 1a and 1b, the device of the present invention includes a
激光器1、激光导光装置4和激光聚焦装置3位于同一光路上，激光器1发射出来的激光束经激光导光装置4传输到激光聚焦装置3，经聚焦后照射至待加工工件表面的预置涂层。The
感应加热线圈8与高频感应加热器2相连，用于对待加工工件9进行加热。导气管11的出气口位于激光聚焦装置3的出光口处，在导气管11中通入保护气体，可避免待加工工件氧化。The
工件夹持装置安装在数控机床6上，数控机床6可以采用三轴或四轴联动的数控机床。工件夹持装置由旋转工作台5、三爪卡盘7和顶针10构成。旋转工作台5固定在数控机床6上，旋转工作台5上安装有三爪卡盘7。顶针10固定在数控机床6上，其位置与三爪卡盘7相对。三爪卡盘7和顶针10用于夹持待加工工件9。The workpiece clamping device is installed on the numerically controlled
如图2所示，激光感应复合熔覆时，感应加热线圈8套在待加工工件9外，感应加热线圈8与待加工工件9外表面涂层之间的距离为1-10毫米。加工完成后，在待加工工件9的外壁形成高性能熔覆材料层12。As shown in Figure 2, during laser induction composite cladding, the
感应加热线圈8可以是单匝或多匝，线圈的形状可以是圆形(如图2所示)或半圆环形(如图3所示)。为操作方便，半圆环形多匝感应加热线圈8位于待加工工件9的下方，激光束的出光口位于待加工工件9的上方，并定位到感应加热区，也可以实现预热与后热同时进行的激光熔覆处理。The
对于大型的管状工件或实心部件，如图4所示，工件夹持装置由一对旋转工作台5、5’和一对三爪卡盘7、7’构成。旋转工作台5、5’安装在数控机床6上，三爪卡盘7、7’分别安装在旋转工作台5、5’。二个三爪卡盘7、7’将待加工工件9的两端固定，旋转工作台5、5’带动待加工工件9旋转，并随数控机床6一起移动。For large tubular workpieces or solid components, as shown in Figure 4, the workpiece clamping device consists of a pair of rotary tables 5, 5' and a pair of three-
如图5所示，当对待加工工件的内壁进行处理时，感应加热线圈8和激光聚焦装置3的出光口应位于待加工工件9的内壁内，感应加热线圈8与待加工工件9的内壁涂层间的距离为1-10毫米。需要利用专用的激光导光装置将激光束引入管件内腔。激光导光装置4如图6所示，由“”型的导光管15和两个反射镜13与14构成。第一反射镜14位于导光管15的拐角处，第二反射镜13位于导光管15出光端，反射镜13、14的镜面相互平行，并且与激光光轴的夹角均为45°。激光器1发射出的激光束经导光装置4传输到激光聚焦装置3聚焦后辐照在待加工工件9的涂层表面。As shown in Figure 5, when the inner wall of the workpiece to be processed is processed, the light outlet of the
如图7所示，为提高感应加热线圈8对待加工工件9的加热效率，在感应加热线圈8上安装有导磁体16。As shown in FIG. 7 , in order to improve the heating efficiency of the
实例：Example:
实例1：Example 1:
选择连续CO2激光器，采用如图1a所示的装置对外径为110毫米、壁厚为10毫米的管状金属零部件的外表面进行激光感应复合熔覆处理。A continuousCO2 laser is selected, and the outer surface of a tubular metal part with an outer diameter of 110 mm and a wall thickness of 10 mm is used for laser induction composite cladding treatment using the device shown in Figure 1a.
(1)先对管状金属零部件的外表面进行喷砂处理；(1) Sand blasting is carried out to the outer surface of the tubular metal parts;
(2)采用热喷涂或者冷喷涂技术，在外表面喷涂厚度为0.1毫米的涂层。涂层材料可以选择耐磨、耐蚀或者耐高温的铁基、镍基或者钴基合金粉末，也可以选择上述合金粉末与碳化钨、碳化钛、碳化硅等陶瓷颗粒组成的金属陶瓷复合粉末。(2) Use thermal spraying or cold spraying technology to spray a coating with a thickness of 0.1 mm on the outer surface. The coating material can choose wear-resistant, corrosion-resistant or high-temperature-resistant iron-based, nickel-based or cobalt-based alloy powders, or cermet composite powders composed of the above alloy powders and ceramic particles such as tungsten carbide, titanium carbide, and silicon carbide.
(3)将管状金属零部件外表面的涂层与感应加热线圈之间的距离调节为1毫米，感应加热线圈的匝数为3匝，在感应加热线圈中通入电流，调节感应加热功率，使管状金属零部件表面的温度为500-750℃。(3) The distance between the coating on the outer surface of the tubular metal part and the induction heating coil is adjusted to 1 mm, the number of turns of the induction heating coil is 3 turns, and an electric current is passed into the induction heating coil to adjust the induction heating power, The temperature of the surface of the tubular metal part is made to be 500-750°C.
(4)将激光束定位到感应加热线圈之间，实现对管状金属零部件表面涂层的预热与后热同时进行的激光熔覆加工，用于预热与后热的线圈匝数分别为2匝与1匝。激光聚焦装置将经过激光导光装置传输来的激光束聚焦后辐照在管状金属零部件外表面的涂层上，光斑的直径为30毫米，聚焦光斑的位置位于感应加热区的几何中心处。激光器的输出功率为5KW，激光熔覆的线速度为3米/分钟。采用多道搭接方式，完成管状金属零部件外表面的大面积熔覆。激光熔覆过程中，相邻激光熔覆层之间的搭接率为30％。(4) The laser beam is positioned between the induction heating coils to realize the simultaneous laser cladding process of preheating and postheating of the surface coating of tubular metal parts. The coil turns for preheating and postheating are respectively 2 turns vs. 1 turn. The laser focusing device focuses the laser beam transmitted by the laser light guide device and then irradiates it on the coating on the outer surface of the tubular metal part. The diameter of the spot is 30 mm, and the focused spot is located at the geometric center of the induction heating zone. The output power of the laser is 5KW, and the line speed of laser cladding is 3 m/min. A large-area cladding of the outer surface of tubular metal parts is completed by adopting a multi-pass overlapping method. During the laser cladding process, the overlapping rate between adjacent laser cladding layers is 30%.
(5)当熔覆完一层之后，继续采用热喷涂、冷喷涂或者其它涂覆方式在管材外壁预置一层厚0.1毫米的涂层，然后重复步骤(3)-(4)。如此反复，直到熔覆层的厚度达到所需要的工况要求。(5) After cladding one layer, continue to use thermal spraying, cold spraying or other coating methods to preset a layer of coating with a thickness of 0.1 mm on the outer wall of the pipe, and then repeat steps (3)-(4). Repeat this until the thickness of the cladding layer reaches the required working conditions.
实例2：Example 2:
选择二极管激光器，采用如图1b所示的装置对外径为300毫米、壁厚为15毫米的管状金属零部件的外表面进行激光感应复合熔覆处理。Choose a diode laser, and use the device shown in Figure 1b to perform laser induction composite cladding on the outer surface of a tubular metal part with an outer diameter of 300 mm and a wall thickness of 15 mm.
(1)先对管状金属零部件的外表面进行喷砂处理；(1) Sand blasting is carried out to the outer surface of the tubular metal parts;
(2)采用热喷涂、冷喷涂技术或超音速火焰喷涂技术，在外表面喷涂厚度为3.0毫米的涂层。涂层材料可以选择耐磨、耐蚀或者耐高温的铁基、镍基或者钴基合金粉末，也可以选择上述合金粉末与碳化钨、碳化钛、碳化硅等陶瓷颗粒组成的金属陶瓷复合粉末。(2) Use thermal spraying, cold spraying technology or supersonic flame spraying technology to spray a coating with a thickness of 3.0 mm on the outer surface. The coating material can choose wear-resistant, corrosion-resistant or high-temperature-resistant iron-based, nickel-based or cobalt-based alloy powders, or cermet composite powders composed of the above alloy powders and ceramic particles such as tungsten carbide, titanium carbide, and silicon carbide.
(3)将管状金属零部件外表面的涂层与感应加热线圈之间的距离调节为10毫米，感应加热线圈的匝数为3匝，在感应加热线圈中通入电流，高频感应加热器可以在数秒钟之内将管状金属零部件表面加热到红热状态，调节感应加热功率，使管状金属零部件外表面的温度为1000-1200℃。(3) The distance between the coating on the outer surface of the tubular metal part and the induction heating coil is adjusted to 10 mm, the number of turns of the induction heating coil is 3 turns, and a current is passed into the induction heating coil, and the high-frequency induction heater The surface of the tubular metal parts can be heated to a red-hot state within a few seconds, and the induction heating power can be adjusted so that the temperature of the outer surface of the tubular metal parts is 1000-1200°C.
(4)将激光束定位到感应加热线圈之后25毫米的感应加热区内，进行激光熔覆处理。激光聚焦装置将经过激光导光装置传输来的激光束聚焦后辐照在管状金属零部件外表面的涂层上，光斑的直径为2毫米，聚焦光斑的位置位于感应加热区的几何中心处。激光器的输出功率为5KW，激光熔覆的线速度为10米/分钟。采用多道搭接方式，完成管状金属零部件外表面的大面积熔覆。激光熔覆过程中，相邻激光熔覆层之间的搭接率为70％。(4) Position the laser beam in the induction heating zone 25mm behind the induction heating coil, and perform laser cladding treatment. The laser focusing device focuses the laser beam transmitted by the laser light guide device and then irradiates it on the coating on the outer surface of the tubular metal part. The diameter of the spot is 2 mm, and the position of the focused spot is located at the geometric center of the induction heating zone. The output power of the laser is 5KW, and the line speed of laser cladding is 10 m/min. A large-area cladding of the outer surface of tubular metal parts is completed by adopting a multi-pass overlapping method. During the laser cladding process, the overlapping rate between adjacent laser cladding layers is 70%.
(5)当熔覆完一层之后，继续采用热喷涂、冷喷涂或者其它涂覆方式在管材外壁预置一层厚3.0毫米的涂层，然后重复步骤(3)-(4)。如此反复，直到熔覆层的厚度达到所需要的工况要求。(5) After cladding one layer, continue to use thermal spraying, cold spraying or other coating methods to preset a layer of coating with a thickness of 3.0 mm on the outer wall of the pipe, and then repeat steps (3)-(4). Repeat this until the thickness of the cladding layer reaches the required working conditions.
实例3：Example 3:
选择连续CO2激光器，采用如图4所示的装置对辊径D＝600毫米的轧辊表面进行激光感应复合熔覆处理，同时该装置也适用于曲轴、石油钻杆等实心部件。Select the continuousCO2 laser, and use the device shown in Figure 4 to perform laser induction composite cladding on the surface of the roll with a diameter of D = 600 mm. At the same time, this device is also suitable for solid parts such as crankshafts and oil drill pipes.
(1)先对轧辊表面进行喷砂处理；(1) Sandblasting the surface of the roll first;
(2)采用热喷涂、冷喷涂技术或超音速火焰喷涂技术，在轧辊表面喷涂厚度为1毫米的涂层。涂层材料可以选择耐磨、耐蚀或者耐高温的铁基、镍基或者钴基合金粉末，也可以选择上述合金粉末与碳化钨、碳化钛、碳化硅等陶瓷颗粒组成的金属陶瓷复合粉末。(2) Use thermal spraying, cold spraying technology or supersonic flame spraying technology to spray a coating with a thickness of 1 mm on the surface of the roll. The coating material can choose wear-resistant, corrosion-resistant or high-temperature-resistant iron-based, nickel-based or cobalt-based alloy powders, or cermet composite powders composed of the above alloy powders and ceramic particles such as tungsten carbide, titanium carbide, and silicon carbide.
(3)将轧辊金属零部件表面的涂层与感应加热线圈之间的距离调节为5毫米，感应加热线圈的匝数为4匝，在感应加热线圈中通入电流，调节感应加热功率，使轧辊金属零部件表面的温度为700-900℃。(3) The distance between the coating on the surface of the metal parts of the roll and the induction heating coil is adjusted to 5 millimeters, the number of turns of the induction heating coil is 4 turns, and an electric current is passed into the induction heating coil to adjust the induction heating power so that The surface temperature of the roll metal parts is 700-900°C.
(4)将激光束定位到感应加热线圈之间，实现对轧辊表面涂层的预热与后热同时进行的激光熔覆加工，用于预热与后热的线圈匝数都为2匝。激光聚焦装置将经激光导光装置传输来的激光束聚焦后辐照在轧辊金属零部件表面，光斑的直径为20毫米，聚焦光斑的位置位于感应加热区的几何中心区。激光器的输出功率为8KW，激光熔覆的线速度8米/分钟。采用多道搭接方式，完成轧辊金属零部件的大面积熔覆。激光熔覆过程中，相邻激光熔覆层之间的搭接率为50％。(4) The laser beam is positioned between the induction heating coils to realize the simultaneous laser cladding process of preheating and postheating of the roll surface coating, and the number of coil turns for both preheating and postheating is 2 turns. The laser focusing device focuses the laser beam transmitted by the laser light guide device and then irradiates it on the surface of the metal part of the roll. The diameter of the spot is 20mm, and the position of the focused spot is located in the geometric center of the induction heating zone. The output power of the laser is 8KW, and the line speed of laser cladding is 8 m/min. The multi-pass overlapping method is used to complete the large-area cladding of the metal parts of the roll. During the laser cladding process, the overlapping rate between adjacent laser cladding layers is 50%.
(5)当熔覆完一层之后，继续采用热喷涂、冷喷涂或者其它涂覆方式在轧辊表面预置一层厚1毫米的涂层材料，然后重复步骤(3)-(4)。如此反复，直到轧辊表面熔覆层厚度达到所需要的工况要求。(5) After cladding one layer, continue to use thermal spraying, cold spraying or other coating methods to preset a layer of coating material with a thickness of 1 mm on the surface of the roll, and then repeat steps (3)-(4). This is repeated until the thickness of the cladding layer on the surface of the roll reaches the required working conditions.
实例4：Example 4:
选择连续CO2激光器，采用如图5所示的装置对外径为110毫米、壁厚为10毫米的管材内表面进行激光感应复合熔覆处理。The continuousCO2 laser is selected, and the inner surface of the pipe with an outer diameter of 110 mm and a wall thickness of 10 mm is used for laser induction composite cladding treatment using the device shown in Figure 5.
(1)先将管材内表面进行喷砂处理；(1) Sand blast the inner surface of the pipe first;
(2)采用热喷涂技术、冷喷涂或者其它技术在管材的内表面预置厚度为2.0毫米的涂层，涂层材料可根据实际工况的需求，选择高性能铁基、镍基或者钴基合金粉末。(2) Use thermal spraying technology, cold spraying or other technologies to pre-set a coating with a thickness of 2.0mm on the inner surface of the pipe. The coating material can be selected from high-performance iron-based, nickel-based or cobalt-based according to the actual working conditions. alloy powder.
(3)调整内表面涂层与感应加热线圈之间的距离，使其间距为8毫米，感应加热线圈的匝数为2匝，在感应加热线圈中通入电流，感应加热线圈可以在数秒内将管材内表面加热到红热状态，调节感应加热功率，使管材内表面的温度为900℃-1100℃。(3) Adjust the distance between the inner surface coating and the induction heating coil so that the distance is 8 mm, the number of turns of the induction heating coil is 2 turns, and the current is passed into the induction heating coil. Heat the inner surface of the pipe to a red-hot state, and adjust the induction heating power so that the temperature of the inner surface of the pipe is 900°C-1100°C.
(4)将激光束经激光导光装置输入到管材内壁，激光聚焦装置将经激光导光装置传输来的激光束聚焦后辐照在管材内壁表面的涂层上，光斑的直径为10毫米，然后将激光束定位到感应加热线圈之后15毫米的感应加热区内，进行激光感应复合熔覆处理。激光输出功率为5KW，激光熔覆的线速度为5米/分钟，利用多道搭接技术在管材内壁均匀熔覆一层高性能材料涂层，激光熔覆过程中，单道激光熔覆层之间的搭接率为60％。(4) The laser beam is input to the inner wall of the pipe through the laser light guide device, and the laser focusing device focuses the laser beam transmitted through the laser light guide device and then irradiates it on the coating on the inner wall surface of the pipe. The diameter of the spot is 10 mm. The laser beam is then positioned in the 15 mm induction heating zone behind the induction heating coil for laser induction composite cladding. The laser output power is 5KW, and the linear speed of laser cladding is 5 m/min. A layer of high-performance material coating is evenly clad on the inner wall of the pipe by using multi-pass lapping technology. During the laser cladding process, the single-pass laser cladding layer The overlap rate between them is 60%.
(5)当熔覆完一层之后，继续热喷涂一层厚为2毫米的涂层材料，然后重复步骤(3)到(4)，直到内壁熔覆层的厚度达到所需要的技术指标。(5) After cladding one layer, continue to thermal spray a layer of coating material with a thickness of 2 mm, and then repeat steps (3) to (4) until the thickness of the cladding layer on the inner wall reaches the required technical index.
本发明的范围并不局限于上述实例，本领域一般人员根据本发明公开的内容，可以采用其它多种方式实现本发明的技术方案。The scope of the present invention is not limited to the above examples, and those skilled in the art can implement the technical solution of the present invention in various other ways according to the content disclosed in the present invention.
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